The Step-by-Step Sachet Filling Process is essential for manufacturers looking to package powders, liquids, granules, and pastes efficiently and cost-effectively. Sachet packaging is widely used across industries such as food, pharmaceuticals, cosmetics, chemicals, and household products because it offers portion control, reduced waste, and convenient single-use packaging.
For businesses in South Africa looking to scale production, understanding each stage of the sachet filling process helps improve efficiency, reduce downtime, and maintain product quality.
In this guide, we break down the full sachet packaging workflow — from film loading to final product discharge.
The process begins with loading a roll of flexible packaging film onto the sachet machine.
The film is typically laminated material designed to provide:
Moisture barrier protection
Oxygen resistance
Extended shelf life
Strong sealing capability
Modern sachet machines use automated film unwinding systems that maintain consistent tension. This ensures proper alignment and prevents wrinkles that could compromise seal integrity.
If the sachets require branding, batch codes, expiry dates, or registration marks, printing occurs either:
Pre-printed on the film
Inline via coding systems
Photoelectric sensors detect registration marks to ensure accurate alignment during sealing and cutting.
The flat film is shaped into a tube using a forming collar. The edges of the film overlap and are sealed vertically to create a continuous tube.
At this stage, the machine prepares individual sachet compartments.
Depending on production needs, manufacturers may use:
3-side seal sachets
4-side seal sachets
Center seal sachets
Multi-lane sachet systems for high output
This forming stage is critical to ensure uniform pouch dimensions.
The filling stage is the core of the Step-by-Step Sachet Filling Process.
Different dosing systems are used depending on product type:
Auger fillers provide precise volumetric dosing
Ideal for coffee, spices, protein powder, and pharmaceutical powders
Piston fillers ensure accurate liquid measurement
Suitable for sauces, oils, creams, and syrups
Cup fillers or weighers measure consistent portions
Common for sugar, salt, and seeds
Accuracy at this stage prevents product giveaway and ensures compliance with weight regulations.
Once the product is dispensed into the formed sachet, horizontal sealing jaws close to seal the top and bottom edges.
Heat and pressure are applied to:
Secure product inside
Prevent leaks
Maintain freshness
Seal strength is vital for transportation durability, especially for products distributed across South Africa and neighboring countries.
After sealing, the machine cuts between sachets to create individual units.
Cutting options include:
Straight cut
Zig-zag cut
Easy-tear notch
The separated sachets then move to the discharge conveyor.
Modern sachet lines incorporate quality control systems such as:
Checkweighers
Metal detectors
Vision inspection systems
These systems detect:
Underfilled or overfilled sachets
Seal defects
Contamination
Automated rejection systems remove defective units without stopping production.
Finished sachets are discharged onto conveyors and prepared for:
Cartoning
Case packing
Shrink wrapping
Palletizing
Automation at this stage improves overall production speed and reduces labor costs.
Implementing an automated sachet packaging system offers:
For South African manufacturers, automation helps remain competitive in both local and export markets.
The sachet filling process is widely used in:
Food & Beverage (sugar, sauces, coffee)
Pharmaceuticals (oral powders, supplements)
Cosmetics (shampoo, lotion samples)
Agriculture (fertilizer samples)
Chemical industry (detergents, cleaning products)
When selecting equipment, consider:
Product type (powder, liquid, paste, granule)
Required output speed
Sachet size range
Film compatibility
Available factory space
Budget and ROI
Multi-lane sachet machines are ideal for high-volume production, while single-lane systems suit smaller operations or startups.
Looking to implement a reliable Step-by-Step Sachet Filling Process in your factory?
We supply high-performance sachet filling machines tailored to South African manufacturers across food, pharmaceutical, cosmetic, and chemical industries.
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Let us help you streamline your packaging line and increase production efficiency.
Powders, liquids, pastes, granules, and semi-solid products can all be packed using appropriate dosing systems.
Modern machines can achieve dosing accuracy within ±1%, depending on product type and calibration.
Single-lane machines can produce 30–80 sachets per minute, while multi-lane systems can exceed 300 sachets per minute.
Yes. Sachets reduce material usage, lower shipping costs, and are ideal for single-use applications.
Yes. Most modern systems are designed for seamless integration with upstream and downstream equipment.
